Magnetic recoil fastener assembly for in-wall speaker installations

ABSTRACT

A magnetic recoil fastener assembly comprises a fastener with a head and a shank, and two annular magnets. When assembled, the annular magnets are arranged on the shank of the fastener to magnetically repel each other. At least the magnet arranged closer to the head of the fastener has a varying inner diameter of its axial opening, including a first diameter at one end which is larger than the width of the head, and a second diameter which is smaller than the width of the head. The end having the larger first diameter is arranged facing the head of the fastener. Also described are in-wall speaker assemblies including such magnetic recoil fastener assemblies for magnetically mounting speaker grilles in an adjustable manner, as well as methods for installing such in-wall speaker assemblies using such magnetic recoil fastener assemblies.

BACKGROUND

The background of the present disclosure relates to in-wall speakerinstallations. In-wall speaker installations allow for an audio systemwithout occupying open room space, compared to freestanding speakers andon-wall mounted speakers. In-wall speakers can include woofer, midrangeand/or tweeter speakers and can be installed in vertical walls, ceilingsand/or floors. It is generally desirable that in-wall speakers provide apleasing aesthetic with the surrounding wall surface. For example, anin-wall speaker's appearance may be minimalized to only its speakergrille for a clean look. In which case, it can be preferable that theposition of the speaker grille is flush with the surrounding wallsurface, that the means for mounting the grille are not visible from theroom space, and that the grille is readily removeable for purposes ofcleaning, replacement, painting, etc.

For these reasons, some in-wall speaker assemblies have used magnets tomount metal speaker grilles. In one approach, a ring-shaped speakergrille mounting component is spaced apart from a separate anchoringstructure, which structure may be a part of a speaker housing or awoofer connector port depending on the type of speaker. The ringcomponent is coupled to the anchoring structure by screws, with the freeends of the screw shanks being inserted into the anchoring structure andthe screw heads being provided on a ring-shaped end surface of the ringcomponent opposite the anchoring structure. The ring component ismechanically biased outward from the anchoring structure by springspositioned between the ring component and the anchoring structure. Theend surface of the ring component opposite the anchoring structure andsprings also carries magnets, to which the grille is magneticallycoupled. The magnets are positioned along this ring-shaped surface alongwith the heads of the screws. The position and plane of the ringcomponent, and thus the position and plane of the magnets for mountingthe speaker grille, can be adjusted by tightening one or more screwsinward against the spring force and/or by loosening one or more screwsoutward away from the anchoring component. While this approach allowsfor a magnetic and adjustable mounting of the speaker grille, it is alsorelatively complex requiring numerous components as well as mechanicalspring mechanisms.

The foregoing examples of the related art and limitations therewith areintended to be illustrative and not exclusive. Other limitations of therelated art will become apparent to those of skill in the art upon areading of the specification and a study of the drawings.

SUMMARY

The following embodiments and aspects thereof are described and depictedin conjunction with systems, tool and methods which are meant to beillustrative, not limiting in scope. In various embodiments, one or moreproblems above have been reduced or eliminated, while other embodimentsare directed to other improvements.

Proceeding from this background, the present disclosure proposes amagnetic recoil fastener assembly, and in particular a magnetic recoilfastener assembly for use with such in-wall speaker installations,though various other use applications are also available. Such afastener assembly comprises a fastener and two magnets. The fastener hasa head at one end and a shank extending from the head. The side of thehead facing the free end of the shank forms a magnet contact surface forthe first magnet. The first magnet is ring-shaped with a fastenerinsertion opening for receiving the fastener. The fastener insertionopening of the first magnet has a first inner diameter and a secondinner diameter. The first inner diameter is larger than the diameter ofthe head of the fastener. The second inner diameter is smaller than thediameter of the fastener head, but larger than the diameter of thefastener shank. A fastener contact surface of the first magnet is thusprovided between the first inner diameter and the second inner diameterwithin the fastener insertion opening. The second magnet is alsoring-shaped with a fastener insertion opening for receiving thefastener. The fastener insertion opening of the second magnet is atleast larger than the diameter of the shank of the fastener.

When assembled, the first and second magnets are arranged along theshank of the fastener to magnetically repel each other, with the firstmagnet being disposed closer to the head of the fastener than the secondring magnet. Therefore, the first magnet is magnetically biased alongthe shank in the direction of the head, such that the fastener contactsurface of the first magnet contacts the magnet contact surface of thefastener head. The first magnet can be used to carry a mounted elementmade of a magnetic material, such as a speaker grille or an intermediaryinstallation part for an in-wall speaker assembly. Multiple fastenerassemblies can be used depending on the carrying requirements for themounted element.

In use, the fastener will be anchored with respect to a substrate. Byadjusting the depth of the fastener shank with respect to the substrate,the position of the first magnet in its biased position against thefastener head is also adjusted. In this way, the position and plane of amounted element may also be adjusted. The first magnet, and a mountedelement thereon, can be pushed against the magnetic force in thedirection of second magnet. This movement may be used to break a drywallor paint seal, for example, where the mounted element is an intermediarycomponent such as a sanding or painting shield used during aninstallation process.

For speaker applications in particular, it is preferable if thesubstrate comprises a magnetic material such that the second magnet willmagnetically attach to the substrate, and/or the space between the firstand second magnets when assembled is such that the second magnet isbiased into secure contact with the substrate due to its magnetic forceinteraction with the first magnet. This can reduce or eliminatevibration of the second magnet on the fastener shank caused by audiooutput, which vibration could result in an undesirable rattling noiseobserved by the listener. Likewise, the magnetic repulsion between thefirst and second magnets can reduce or eliminate vibration of the firstmagnet on the fastener shank, since the first magnet is biased intocontact with the fastener head.

In general, an adjustable magnetic mounting system may include at leastone such magnetic recoil fastener assembly, and further comprise asurface which surrounds an opening formed in the surface, a substratelocated within the opening and at a distance from the surfacesurrounding the opening, and a mounted element (e.g., a speaker grilleor vent cover) shaped to cover the opening. When assembled, the at leastone fastener assembly is arranged within the opening, with the shank ofthe at least one fastener assembly anchored with respect to thesubstrate, and the mounted element is magnetically attached to the firstring magnet of the at least one fastener assembly, such that apositional plane of the mounted element is adjustable by adjusting adepth of the fastener of the at least one fastener assembly relative tothe substrate. A method for mounting the mounted element with thissystem may comprise: anchoring the shank of the at least one fastenerassembly to the substrate within the opening; magnetically attaching themounted element to the first magnet of the at least one fastenerassembly within the opening; and if the positional plane of the mountedelement is not flush with the surface surrounding the opening, thenadjusting the depth of the fastener of the at least one fastenerassembly relative to the substrate, such that the positional plane ofthe mounted element is flush with the surface surrounding the opening.

The preceding discussion is provided to introduce a selection ofconcepts in a simplified form that are further described below. Thepreceding discussion is not intended to identify key or essentialfeatures of the claimed subject matter, nor is it intended to be used tolimit the scope of the claimed subject matter. Other features, details,utilities, and advantages will be apparent from the below descriptionsof various implementations as further illustrated in the accompanyingdrawings, wherein like reference characters designate correspondingparts in the several views.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure is described hereinafter based on illustrativeembodiments with reference to the following figures:

FIG. 1 shows a side view of an example fastener assembly mounted on asubstrate;

FIG. 2 shows a side view of the fastener assembly of FIG. 1 in a secondposition;

FIG. 3 shows a sectional view of the fastener assembly of FIG. 1;

FIG. 4 shows a sectional view of the fastener assembly of FIG. 2;

FIG. 5 shows a side view of an example fastener assembly mounted on asubstrate;

FIG. 6 shows a side view of the fastener assembly of FIG. 5 in a secondposition;

FIG. 7 shows a sectional view of the fastener assembly of FIG. 5;

FIG. 8 shows a sectional view of the fastener assembly of FIG. 6;

FIG. 9 shows the first magnet of FIGS. 3 and 4 by itself;

FIG. 10 shows the magnet of FIG. 9 in another embodiment;

FIG. 11 shows the first magnet of FIGS. 7 and 8 by itself;

FIG. 12 shows the magnet of FIG. 11 in another embodiment;

FIG. 13 shows a schematic side sectional view of the head portion of afastener assembly with an element thereon in a first position;

FIG. 14 shows the fastener assembly of FIG. 13 in a second position;

FIG. 15 shows a side view of a speaker assembly;

FIG. 16 shows a bottom view of the speaker assembly of FIG. 15;

FIG. 17 shows the speaker port of FIG. 16 with the grille removed;

FIG. 18 shows a bottom perspective view of the speaker port of thespeaker assembly of FIGS. 15-17 by itself;

FIG. 19 shows the speaker port of FIG. 18 with a platform componentmounted therein carrying fastener assemblies;

FIG. 20 shows the platform component of FIG. 19 by itself;

FIG. 21 shows a bottom perspective view of a shield assembly; and

FIG. 22 shows a top perspective exploded view of the shield assembly ofFIG. 21.

Before explaining the depicted embodiments, it is to be understood thatthe invention is not limited in its application to the details of theparticular arrangements shown, since the invention is capable of otherembodiments. It is intended that the embodiments and figures disclosedherein are to be considered illustrative rather than limiting. Also, theterminology used herein is for the purposes of description and notlimitation.

DETAILED DESCRIPTION

Certain terminology is used in the following description for thepurposes of clear and concise explanation, which should not beconsidered or construed as limiting. For example, terms such as“connected” or “attached” include both directly and indirectly connectedor attached, respectively, unless expressly indicated otherwise. Thisapplies not only to these specific terms, but also to similar, related,and derivative terms and phrases as well.

Referring now to FIGS. 1-4, a fastener assembly 100 comprises a fastener110, a first magnet 120, and a second magnet 130. The assembly 100 isshown mounted onto a substrate 10. The fastener 110 has a head 112 atone end and a shank 114 extending therefrom. The side of the head 112facing in the direction of the shank 114 provides a magnet contactsurface 116, which interfaces with a fastener contact surface 122 of thefirst magnet 120. The fastener 110 itself may be made from a magnetic ornon-magnetic material.

The first magnet 120 and second magnet 130 are annular or ring-shapedmagnets with a center aperture or insertion opening 124 through whichthe shank 114 of the fastener 110 is inserted when assembled. Themagnets 120, 130 are arranged on the fastener 110 in a manner tomagnetically repel each other. The opposing orientation of the north andsouth poles of magnets 120, 130 is shown by the “N” and “S” labeledarrows in FIGS. 1 and 2.

At least the first magnet 120 has a varying inner diameter dimension. Asbetter seen in FIG. 9, a first inner diameter 126 of the fastenerinsertion opening 124 is larger than the diameter of the head 112 of thefastener 110, such that the head 112 can pass through a portion of themagnet 120 with this dimension 126. A second inner diameter 128 of thefastener insertion opening 124 is smaller than the diameter of the head112—such that the magnet 120 cannot be pulled off the fastener 110 inthe direction of the head 112—but larger than the diameter of the shank114 such that the magnet 120 can be displaced along the shank 114 to thehead 112. The fastener contact surface 122 of the magnet 120 is providedwithin the fastener insertion opening 124 and extends between the firstinner diameter 126 and the second inner diameter 128.

Due to the opposing magnetic force between the magnets 120, 130described above, the first magnet 120 is biased against the head 112 inFIGS. 1 and 3. In this position, the fastener contact surface 122 of themagnet 120 abuts the magnet contact surface 116 of the head 112. InFIGS. 2 and 4, the first magnet 120 has been moved along the shank 114in a direction away from the head 112 against the magnetic force of thesecond magnet 130. In this position, the fastener contact surface 122 ismoved away from and no longer contacts the magnet contact surface 116.In some applications, it is advantageous if the space between the firstand second magnets 120, 130 when assembled is selected to be smallenough to securely bias the second magnet 120 against the substrate 10via the magnetic field interaction between the first and second magnets120, 130 (the size of the space being variable depending on thestrengths of the magnets used), and/or if the substrate 10 comprises amagnetic material such that the second magnet 130 is magneticallycoupled to the substrate 10.

FIGS. 4-8 show another embodiment of the fastener assembly 100. Theprevious discussion applies equally here except as otherwise indicated.In this embodiment, the extension of the first magnet 120 along thelongitudinal axis of the fastener 110, and the portion of the fastenerinsertion opening 124 of the first magnet 120 with the larger firstinner diameter 126, is greater than in the previous embodiment of FIGS.1-4 (also compare FIG. 9 with FIG. 11). Therefore, compared to theprevious embodiment, the first magnet 120 can be moved from its positionbiased against the head 112 (see FIGS. 5 and 7) against the opposingmagnetic force provided by the second magnet 130 farther along thefastener 110 before the end of the magnet 120 coincides with the planeof the outer end of the head 112 (see FIGS. 6 and 8).

Additionally, the second magnet 130 in the embodiment of FIGS. 5-8 isprovided as a simple annular or ring-shaped magnet with a generallyconstant inner diameter. In the embodiment of FIGS. 1-4, the firstmagnet 120 and the second magnet 130 share the same construction,meaning either magnet can be selected as the first magnet or secondmagnet during assembly. Either embodiment may use either approach, andboth approaches can be advantageous depending on the circumstances. Forexample, it may be more cost effective to use ring magnets without avarying inner diameter construction for the second magnet 130. Or it maybe more cost effective to source and stock a single component for bothmagnets. It may also be beneficial to use the same magnet for the firstand second magnets since the magnets are then readily interchangeableduring assembly and use.

Details described above regarding the fastener contact surface 122,fastener insertion opening 124, first inner diameter 126, second innerdiameter 128 of the first magnet 120 are better visible in FIGS. 9 and11 for the embodiments of FIGS. 1-4 and 5-8, respectively.

FIG. 10 shows an alternative construction for the first magnet 120 ofFIG. 9. In this embodiment, the variable inner diameter of the fastenerinsertion opening 124 is provided as a counterbore, rather than as acountersink as shown in FIG. 9. Therefore, the fastener contact surface122 extends radially from the longitudinal axis between the first innerdiameter 126 and the second inner diameter 128, rather than along thelongitudinal axis at an angle as shown in FIG. 9. In this construction,the fastener head 112 may have a flat underside (not shown) rather thana tapered underside as shown in FIGS. 3 and 4, as is common in manytypes of fasteners, in order to accommodate the interface between themagnet contact surface 116 and the fastener contact surface 122. Ofcourse, the location of the fastener contact surface 122, and thereforethe depth of the first inner diameter 126 along the longitudinal axis,can be varied for a given application as desired. FIG. 12 shows the samealternative construction for the first magnet 120 of FIG. 11.

It should be appreciated that although the fastener 110 is shown as ascrew with threading along its entire shank 114 mated into the substrate10, other fastener configurations may also be used for the assembly 100.As described above, the underside of the head 112—which faces the shank114 and provides the magnet contact surface 116—may be tapered, flat,rounded, etc. The opposite side of the head 112, which faces away fromthe shank 114, may likewise be flat, round, chamfered, etc. The torquedrive for the head 112 may be cross, slot, hex, square, etc. Stillfurther, the fastener 110 may be used with a nut in the manner of abolt. The shank 114 may be unthreaded in portions, particularly sincethe head 112 of the fastener 110 in the assembly 100 is intended to bepositioned away from the substrate 10 in order to accommodate themagnets 120, 130 therebetween, such that threading can be omittedthrough this free area of the shank 114. In sum, a wide variety ofmodifications to the depicted embodiments are possible.

Turning now to FIGS. 13 and 14, a mounted element 140 is schematicallyshown attached to the head portion of a fastener assembly 100 (thesecond magnet 130 is omitted here). The mounted element 140 is made of amagnetic material such that it responds to the magnetic field of thefirst magnet 120 and magnetically couples to the first magnet 120. Theposition of the fastener 110 with respect to substrate 10 (not shown)has been adjusted such that the mounted element 140 is flush with thesurface 150 surrounding the mounted element 140 in FIG. 13. In FIG. 14,the mounted element 140 and the first magnet 120 have been moved in thedirection of the shank 114—against the magnetic force of the secondmagnet 130—until the mounted element 140 is stopped by the head 112 ofthe fastener 110. Generally, the mounted element 140 will be much largerthan shown, such as in the case of a speaker grille, sanding shieldplate, or painting shield plate, and in which case, typically supportedby multiple fastener assemblies 100. In the case of a sanding shieldplate where drywall has been mudded onto element 140 and surfaces 150opposite the fastener assembly 100, for example, the act of pushing themounted element 140 out from the position of FIG. 13 into the positionof FIG. 14 can be used to break the drywall seam between element 140 andsurfaces 150. Likewise, in the case of a painting shield plate wherepaint has been applied onto element 140 and surfaces 150 opposite thefastener assembly 100, for example, the act of pushing the mountedelement 140 out from the position of FIG. 13 into the position of FIG.14 can be used to break the paint seam between element 140 and surfaces150.

Turning now to FIGS. 15-17, a speaker assembly 200 is shown for aceiling-mounted drywall installation. An assembly mounting panel 202will replace a portion of the regular ceiling drywall and be secured toone or more load-bearing structures (e.g. building framing). This may bea new build or retrofit installation. A bracket 204 is provided on thetop side of the panel 202 for securing, via fasteners 206, a speakerport 210 to the panel 202 in a clamping manner. As better seen in FIG.18, the speaker port 210 is generally constructed as a hollow cylinder212 with a perforated mud plate 214 extending radially outward from anend of the cylinder 212. As described in more detail below, bosses 216are provided along the interior surface of the cylinder 212 (only oneboss 216 is visible in the view of FIG. 18; the other boss 217 here isused to attach the midrange speaker 208 to the speaker port 210). Thespeaker port 210 has a mud dam 218 which projects outward from theperforated mud plate 214 around the opening of the hollow cylinder 212.The mud dam 218 is the portion of the speaker port 210 visible on thebottom side of the panel 202 in FIG. 15; the mud plate 214 is otherwisepositioned in a recess formed in the bottom side of the panel 202 andtherefore not visible in the side profile view of FIG. 15. Of course, itshould be appreciated that the foregoing structures of the speaker port210 may instead be designed and provided by separate components, ratherthan a single integral component as shown.

In the depicted assembly 200, a midrange speaker 208 is provided at theend of the speaker port cylinder 212 opposite the perforated mud plate214. A tweeter speaker 220 is provided within the speaker port cylinder212 and coupled to speaker port bosses 216 via fasteners 222. Thetweeter speaker 220 is smaller than the inner diameter of the portcylinder 212 to allow passage of audio output from the midrange speaker208 through the port cylinder 212. Therefore, this speaker assembly 200has good audio range in that the audio output can crossover between thetweeter speaker 220 at higher frequencies to the midrange speaker 208 atlower frequencies, or can be simultaneously output from both speakers.Of course, other embodiments could have just the midrange speaker 208 orjust the tweeter speaker 220. In further embodiments (not shown), theaudio speaker of the speaker assembly 200 is a woofer attached to theend of the port cylinder 212 opposite the mud plate 214 via a port tube.

After installation, a speaker grille 224 will cover the end of thespeaker port cylinder 212 on the side having the mud plate 214 and muddam 218. The speaker grille 224 is made of a magnetic metal or othermaterial, and magnetically coupled to the first magnets 120 of thefastener assemblies 100. In the depicted speaker assembly 200 of FIGS.15-17, the fastener assemblies 100 are anchored in the housing of thetweeter speaker 220 (which therefore provides substrate 10 of theprevious figures).

In speaker assemblies 200 without a tweeter speaker 220 mounted in theport cylinder 212, such as assemblies with a woofer or the midrangespeaker 208 only, the bosses 216 within the cylinder 212 may be used toanchor the fastener assemblies 100 directly. Alternatively, as shown inFIGS. 19 and 20, the cylinder bosses 216 may be used to mount a separateplatform component 226 which then provides the substrate structure forthe fastener assemblies 100. The platform component 226 is designed toextend around the periphery of the interior surface of the cylinder 212to leave the cylinder interior mostly open for passage of audio outputfrom the midrange speaker 208 or woofer. For example, the platformcomponent 226 may have a ring or C shape. The platform component 226provides anchoring points around the periphery of the cylinder 212 forreceiving fastener assemblies 100. In the embodiment of FIGS. 19 and 20,the platform component 226 has a C shape with three bosses 228 intowhich three fastener assemblies 100 are inserted. The fasteners222—which previously coupled the tweeter speaker 220 to bosses 216 inthe arrangement of FIG. 17—couple the platform component 226 to thecylinder bosses 216. The platform component 226 may be readily producedby injection molding, for example, or any other suitable productionmethod.

It should be appreciated that the number, positioning, and spacing ofthe fastener assemblies 100 may be readily selected and modified in viewof the particular carrying requirements for a given application. Forexample, large or heavy speaker grilles 224 (or sanding/paint shieldplates) may require additional fastener assemblies 100, or at leaststrong first magnets 120, to ensure such mounted elements 140 aresufficiently secure. Thus, the tweeter speaker 220 or the platformcomponent 226 may be designed to carry more, or less, fastenerassemblies 100 than depicted, in view of the carrying requirements forthe mounted element 140. Therefore, the separate platform component 226allows the same speaker port 210 to be used, without modification,regardless of the speaker or fastener assembly configuration.

Note that the speaker assembly 200 is shown here prior to drywallmudding, sanding and painting as now described. During installation, thespeaker grille 224 can be replaced by sanding and painting shields,which are removably coupled to together. FIGS. 21 and 22 show onepossible configuration for such installation shields. This shieldassembly 230 comprises a sanding shield plate 232 and a painting shieldplate 234. The plates 232, 234 are coupled together by a fastener 236through the center thereof. The sanding shield plate 232 has an opening238 and the painting shield plate 234 has a stamped tab 240 aligned overthe sanding shield opening 238. At least the painting shield plate 234is made of a magnetic metal or other material in order to magneticallycouple to the first magnets 120 of the fastener assemblies 100. Thesanding shield plate 232 and the painting shield plate 234 generallyhave the same shape as the speaker grille 224, since these componentsstand in for the speaker grille 224 during installation and help ensurea clean final aesthetic. Once the panel 202 has been structurallymounted, the magnetic screw assemblies 100 are adjusted to set thesanding shield plate 232 coplanar with the end of the mud dam 218 of thespeaker port 210.

In a mudding step, the ceiling surrounding the panel 202, the panel 202,the perforated mud plate 214, and at least the edges of the sandingshield plate 232 are mudded with a drywall compound, generally inmultiple layers. Once dry, the mudded drywall is then sanded down to themud dam 218 to produce a smooth ceiling surface. The sanding shieldplate 232, and therefore also the painting shield plate 234, is thenpushed upward along the fastener assemblies 100 to break the drywallseam, as described in reference to FIGS. 13 and 14, and the sandingshield plate 232 is removed from the painting shield plate 234. For thedepicted shield assembly 230, the installation shield plates 232, 234are separated by first removing the plate fastener 236. If the sandingshield plate 232 remains in place at that point, a tool (e.g. ascrewdriver) may be inserted through the sanding shield opening 238 toact against the paint shield tab 240 and separate the plates 232, 234from one another.

In a painting step, the sanded ceiling surface is painted through atleast the edges of the painting shield plate 234. The painting shieldplate 234 is then pushed upward along the fastener assemblies 100 tobreak the paint seam, as described in reference to FIGS. 13 and 14, andthe painting shield plate 234 is removed. Again, a tool inserted intothe opening of the paint shield tab 240 may be used, if necessary, topull the paint shield 234 off the fastener assemblies 100.

At this point, the speaker grille 224 may be mounted to the fastenerassemblies 100 in the case of woofer or midrange speaker 208 onlyspeaker assemblies 200, or in the case of the depicted assembly 200 ifthe installation process was performed with the tweeter speaker 220already in place. However, it is typically preferable to mud, sand andpaint without the tweeter speaker 220 being mounted in the port cylinder212. This protects the tweeter speaker 220 from particle ingress duringinstallation, and further, ensures there is adequate room within thecylinder 212 to complete the installation steps depending on thecomponent design dimensions. For example, if the tweeter speaker 220 ispositioned close to the end of the cylinder 212, it could impede orotherwise interfere with setting the sanding/painting shield plates 232,234 in the correct position or moving them to sufficiently break theseams. Such considerations also apply where the sanding/paint shieldplates are coupled together by a fastener which extends, at least bysome amount, longitudinally into the port cylinder 212 past the paintingshield, as is the case with the shield fastener 236 in the depictedshield assembly 230. If the tweeter speaker 220 is not mounted withinthe speaker port 210 during the installation process, the platformcomponent 226 may be used to anchor the fastener assemblies 100 formagnetic coupling with the shield assembly 230. In which case, afterpainting, the platform component 226 is removed from the port cylinder212 to allow the tweeter speaker 220 to then be mounted therein asdescribed above.

In any event, the position of the speaker grille 224 is readily adjustedby varying the depth of the fastener 110 of the one or more fastenerassemblies 100. This adjustment can be used to ensure the speaker grille224 is flush with the surrounding ceiling surface as desired.

Once fully installed and positionally set, the first magnets 120 of thefastener assemblies 100 carrying the speaker grille 224 are in thepositions shown in FIGS. 1, 3, 5, 7 and 13. It should be noted that thefirst magnet 120 is already naturally biased downward against thefastener head 112 by gravity for horizontal ceiling-mounted speakerassemblies 200, meaning the second magnet 130 is not strictly necessaryto bias the first magnet 120 against the fastener head 112 by default.However, the audio output from the speaker assembly 200 has thepotential to vibrate the first magnet 120 and/or grille 224 on thefastener 110, which can cause undesirable rattling sounds during use andthereby decrease the sound quality. The repelling magnetic force of thesecond magnet 130 further biases the first magnet 120 outward againstthe head contact surface 122 and therefore helps to reduce or eliminatesuch vibration. Likewise, the second magnet 130 is preferablymagnetically coupled to substrate 10 to reduce the potential for thesecond magnet 130 to vibrate against the fastener 110 due to audiooutput, and/or the space between the first and second magnets 120, 130along the shank 114 is preferably selected to be small enough such thatthe second magnet 130 is securely biased against the substrate 10 by therepelling magnetic force of the first magnet 120. Such considerationsalso apply for speaker assemblies 200 installed in vertical walls.Depending on the embodiment, the substrate 10 for the fastenerassemblies 100 may be provided by a component of the tweeter speakerhousing 220 as in the depicted speaker assembly 200, or the speaker portcylinder bosses 216 directly, or a separate platform component 226mounted within the speaker port 210 as described above, or any othersuitable anchoring structure.

Although the previous description is in the context of an in-ceilingspeaker assembly with a smooth drywall finish, it should be appreciatedthat the systems and benefits described herein may be realized withvarious other finishes, such as wood, tile, etc., by routinemodification to the installation process and components as needed. Thedisclosed magnetic recoil fastener assemblies may be used to adjust andset a speaker grille and any intermediary installation shields for anin-wall speaker assembly, as desired, regardless of wall finish.

Further, magnetic recoil fastener assemblies, systems and methodsdescribed herein may be used in any other contexts where it is desirableto mount a mounted element relative to a surface in an adjustablemanner, and not just those related to speaker installations. Forexample, the fastener assemblies may be used to mount a vent cover in aduct opening, such that the vent cover sits flush with the wall surfacesurrounding the duct opening. The same applies for other in-wall devicesother than speakers, such as sensors or cameras, in which case thedesign of the mounted covering is readily adaptable to accommodate thefunctionality thereof while allowing for a magnetic attachment to one ormore first magnets of the fastener assemblies (e.g. a magneticperipheral frame with a visually transparent center in the case of acamera). The surrounding surface—relative to which the mounted cover isadjusted—may be provided by non-wall objects as well, such as tables,counters or cabinetry for example. A wide variety of applications anduses are possible.

While a number of aspects and embodiments have been discussed above,those of skill in the art will recognize certain modifications,permutations, additions and sub-combinations therefor. It is thereforeintended that the following appended claims hereinafter introduced areinterpreted to include all such modifications, permutations, additionsand sub-combinations, which are within their true spirit and scope. Eachembodiment described herein has numerous equivalents.

The terms and expressions which have been employed are used as terms ofdescription and not of limitation, and there is no intention in the useof such terms and expressions of excluding any equivalents of thefeatures shown and described or portions thereof, but it is recognizedthat various modifications are possible within the scope of theinvention claimed. Thus, it should be understood that although thepresent invention has been specifically disclosed by preferredembodiments and optional features, modification and variation of theconcepts herein disclosed may be resorted to by those skilled in theart, and that such modifications and variations are considered to bewithin the scope of this invention as defined by the appended claims.Whenever a range is given in the specification, all intermediate rangesand subranges, as well as all individual values included in the rangesgiven are intended to be included in the disclosure. When a Markushgroup or other grouping is used herein, all individual members of thegroup and all combinations and sub-combinations possible of the groupare intended to be individually included in the disclosure.

In general, the terms and phrases used herein have their art-recognizedmeaning, which can be found by reference to standard texts, journalreferences and contexts known to those skilled in the art. The abovedefinitions are provided to clarify their specific use in the context ofthe invention.

LIST OF REFERENCE NUMERALS 10 substrate 100 fastener assembly 110fastener 112 head 114 shank 116 magnet contact surface 120 first magnet122 head contact surface 124 fastener insertion opening 126 first innerdiameter of opening 128 second inner diameter of opening 130 secondmagnet 140 mounted element 150 surrounding surface 200 speaker assembly202 panel 204 bracket 206 bracket fasteners 208 midrange speaker 210speaker port 212 hollow port cylinder 214 perforated mud plate 216 boss217 boss 218 mud dam 220 tweeter speaker 222 tweeter/platform mountingfasteners 224 grille 226 platform component 228 platform boss 230 shieldassembly 232 sanding shield plate 234 painting shield plate 236 shieldplate fastener 238 sanding shield opening 240 painting shield tab

The invention claimed is:
 1. A fastener assembly comprising: a fastenerhaving a head at one end and a shank extending from the head, with anunderside of the head facing the shank extending radially outward toprovide a magnet contact surface; a first ring magnet with a fastenerinsertion opening therethrough for receiving the fastener, the fastenerinsertion opening having a first inner diameter at one end and a secondinner diameter which is smaller than the first inner diameter, whereinthe first inner diameter is larger than a diameter of the head of thefastener, wherein the second inner diameter is smaller than the diameterof the head of the fastener but larger than a diameter of the shank ofthe fastener, and wherein a fastener contact surface of the first ringmagnet extends between the first inner diameter and the second innerdiameter within the fastener insertion opening; a second ring magnetwith a fastener insertion opening therethrough for receiving thefastener, the fastener insertion opening at least larger in diameterthan the shank of the fastener; wherein, when assembled, the first ringmagnet and the second ring magnet are arranged along the shank of thefastener to magnetically repel each other, the first ring magnet beingdisposed closer to the head of the fastener than the second ring magnetand arranged with the end of the fastener insertion opening having thefirst inner diameter facing the head of the fastener, such that thefastener contact surface of the first ring magnet is biased toward themagnet contact surface of the head of the fastener.
 2. The fastenerassembly of claim 1, wherein the fastener contact surface of the firstring magnet extends along a longitudinal axis of the fastener insertionopening and at an angle to said longitudinal axis between the firstinner diameter and the second inner diameter.
 3. The fastener assemblyof claim 1, wherein the fastener contact surface of the first ringmagnet extends radially outward with respect to a longitudinal axis ofthe fastener insertion opening between the first inner diameter and thesecond inner diameter.
 4. The fastener assembly of claim 1, wherein thesecond ring magnet is designed the same as the first ring magnet.
 5. Thefastener assembly of claim 1, wherein the inner diameter of the fastenerinsertion opening of the second ring magnet is constant in extendingbetween opposite ends of the second ring magnet.
 6. The fastenerassembly of claim 1, wherein the fastener is a screw or bolt.
 7. Anadjustable magnetic mounting system including at least one fastenerassembly according to claim 1 and further comprising: a surface whichsurrounds an opening formed in the surface; a substrate located withinthe opening and at a distance from the surface surrounding the opening;a mounted element shaped to cover the opening; wherein, when assembled,the at least one fastener assembly is arranged within the opening, withthe shank of the at least one fastener assembly anchored with respect tothe substrate, and the mounted element is magnetically attached to thefirst ring magnet of the at least one fastener assembly, such that apositional plane of the mounted element is adjustable by adjusting adepth of the fastener of the at least one fastener assembly relative tothe substrate.
 8. The system of claim 7, wherein the surface is providedby a wall, ceiling, floor, counter, table or cabinetry.
 9. The system ofclaim 7, wherein the mounted element is a speaker grille or vent cover.10. The system of claim 7, wherein the second ring magnet of the atleast one fastener assembly magnetically attach to the substrate.
 11. Amethod for mounting the mounted element with the system of claim 7, themethod comprising: anchoring the shank of the at least one fastenerassembly to the substrate within the opening; magnetically attaching themounted element to the first magnet of the at least one fastenerassembly within the opening; and if the positional plane of the mountedelement is not flush with the surface surrounding the opening, thenadjusting the depth of the fastener of the at least one fastenerassembly relative to the substrate, such that the positional plane ofthe mounted element is flush with the surface surrounding the opening.12. A speaker assembly for an in-wall speaker installation, the speakerassembly including a plurality of fastener assemblies according to claim1 and further comprising: a speaker port comprising a hollow portcylinder; a speaker grille shaped to cover an opening of the hollow portcylinder; and a speaker attached to the speaker port; wherein, whenassembled, the fastener assemblies are arranged within the hollow portcylinder of the speaker port, with the shanks of the fastener assembliesanchored with respect to a substrate, and the speaker grille ismagnetically attached to the first ring magnets of the fastenerassemblies, such that a positional plane of the speaker grille isadjustable by adjusting a depth of one or more fasteners of the fastenerassemblies.
 13. The speaker assembly of claim 12, wherein the secondring magnets of the fastener assemblies magnetically attach to thesubstrate.
 14. The speaker assembly of claim 12, wherein the speaker ispositioned in the hollow port cylinder of the speaker port, and ahousing of the speaker provides the substrate for the fastenerassemblies.
 15. The speaker assembly of claim 14, wherein the speaker isfastened with respect to mounting bosses provided within the hollow portcylinder of the speaker port, the mounting bosses formed on an interiorsurface of the hollow port cylinder.
 16. The speaker assembly of claim12, further comprising a platform component positioned in the hollowport cylinder of the speaker port, the platform component having a ringor C shape which extends around an interior surface of the hollow portcylinder, wherein bosses of the platform component provide the substratefor the fastener assemblies.
 17. The speaker assembly of claim 16,wherein the platform component is fastened with respect to mountingbosses provided within the hollow port cylinder of the speaker port, themounting bosses formed on the interior surface of the hollow portcylinder.
 18. The speaker assembly of claim 12, wherein mounting bosseswithin the hollow port cylinder of the speaker port provide thesubstrate for the fastener assemblies, the mounting bosses formed on aninterior surface of the hollow port cylinder.
 19. The speaker assemblyof claim 12, further comprising a mounting panel which mounts to a wall,ceiling or floor, wherein the speaker port is secured to the mountingpanel.
 20. The speaker assembly of claim 19, wherein the speaker portfurther comprises a perforated mud plate extending transversely outwardfrom an end of the hollow port cylinder.
 21. The speaker assembly ofclaim 20, wherein the mud plate has a mud dam which projects outward toform a lip around the opening of the hollow port cylinder.
 22. Thespeaker assembly of claim 12, wherein the speaker is a tweeter speaker,a midrange speaker or a woofer.
 23. A method for installing the speakerassembly according to claim 12 in a surface, wherein the surface isprovided by a wall, ceiling or floor, using a shield assembly whichincludes a sanding plate and a painting plate removably attachedtogether and each shaped to cover the opening of the hollow portcylinder of the speaker port, the method comprising: magneticallymounting the painting plate of the shield assembly to the first ringmagnets of the fastener assemblies in the hollow port cylinder of thespeaker port, and, optionally, adjusting the depth of one or morefasteners of the fastener assemblies such that the sanding plate of theshield assembly aligns with an end of the hollow port cylinder of thespeaker port; mudding a drywall compound onto the surface surroundingthe speaker assembly through to at least edges of the opening of thehollow port cylinder of the speaker port to form a drywall transitionsurface; sanding the drywall transition surface to produce a smoothfinish between the surface surrounding the speaker assembly and theopening of the hollow port cylinder of the speaker port; pushing theshield assembly further into the hollow port cylinder of the speakerport, such that the first ring magnets are displaced along the fastenerstoward the second ring magnets, in order to break any drywall seamsformed between the shield assembly and the speaker port; removing thesanding plate from the painting plate, and, optionally, adjusting thedepth of one or more fasteners of the fastener assemblies such that thepainting plate aligns with the end of the hollow port cylinder of thespeaker port; painting the surface surrounding the speaker assemblythrough to at least the edges of the opening of the hollow port cylinderof the speaker port; pushing the painting plate further into the hollowport cylinder of the speaker port, such that the first ring magnets aredisplaced along the fasteners toward the second ring magnets, in orderto break any paint seams formed between the painting plate and thespeaker port; replacing the paint shield with the speaker grille, and,optionally, adjusting the depth of one or more fasteners of the fastenerassemblies in order to adjust the positional plane of the speakergrille.
 24. The method of claim 23, further comprising, at least beforethe mudding step, mounting a mounting panel of the speaker assembly toalign with a plane of the surface surrounding the speaker assembly,wherein the speaker port is secured to the mounting panel.
 25. Themethod of claim 23, further comprising, at least after the paintingstep, installing the speaker of the speaker assembly into the speakerport.